Manufacture of bi-component continuous filaments and articles made therefrom

Abstract

A bi-component continuous filament has a sheath-core arrangement including a first polymer component forming a sheath and including a polyamide, a polyolefin, or a polyester; a second polymer component forming a core and including a polyamide, a polyolefin, or a polyester; and a binding agent adhering the first polymer component to the second polymer component along a length of the filament such that the filament has a generally uniform cross-sectional shape along the length. The binding agent preferably includes a polyolefin modified by an acid anhydride. Articles made from such bi-component continuous filaments include, for example, bulk continuous filament (BCF) fibers and floor coverings, such as mats, rugs, and carpets.

What is claimed is: 
     
       1. A bi-component continuous filament, comprising:
 (a) a first polymer component forming a sheath and comprising a polyamide or a polyester, wherein the first polymer component does not include a polyolefin; 
 (b) a second polymer component forming a core that is surrounded by the sheath, the second polymer component comprising a polyamide, a polyolefin, or a polyester; and 
 (c) a binding agent adhering the first polymer component to the second polymer component along a length of the filament such that the filament has a generally uniform cross-sectional shape along the length, wherein the binding agent comprises a polyolefin modified by an acid anhydride; wherein each of the first and second polymer components is solution-dyed; wherein a tenacity of the bi-component continuous filament is between 3 and 3.85 grams/denier; and wherein an elongation of the bi-component continuous filament is between 33.61%-37.64%. 
 
     
     
       2. The bi-component continuous filament of  claim 1 , wherein the polyolefin modified by the acid anhydride comprises polyethylene (PE), ethylene-vinyl acetate (EVA), or polypropylene (PP). 
     
     
       3. The bi-component continuous filament of  claim 1 , wherein the acid anhydride comprises maleic anhydride. 
     
     
       4. The bi-component continuous filament of  claim 1 , wherein at least one of the first and second polymer components is solution-dyed with a pigment. 
     
     
       5. The bi-component continuous filament of  claim 1 , wherein at least one of the first and second polymer components is solution-dyed with a pigment and a solvent. 
     
     
       6. The bi-component continuous filament of  claim 1 , wherein the second polymer component forming the core of the bi-component continuous filament comprises a recycled polyamide, or a virgin or recycled polyester. 
     
     
       7. The bi-component continuous filament of  claim 1 , wherein at least one of the first and second polymer components is raw white. 
     
     
       8. The bi-component continuous filament of  claim 1 , wherein the sheath has a tri- lobal or generally circular cross-sectional shape, and wherein the core has a generally circular cross-sectional shape that is generally arranged concentrically or eccentrically relative to the sheath. 
     
     
       9. The bi-component continuous filament of  claim 1 , wherein the second polymer component comprises polyolefin, and wherein the polyolefin comprises polyethylene (PE), ethylene-vinyl acetate (EVA), or polypropylene (PP). 
     
     
       10. The bi-component continuous filament of  claim 1 , wherein at least one of the first and second polymer components comprises polyamide, and wherein the polyamide comprises nylon 6; nylon 6,6; nylon  7 ; nylon 6,10; nylon 6,12; nylon 12; nylon 46; or nylon 1212. 
     
     
       11. The bi-component continuous filament of  claim 1 , wherein at least one of the first and second polymer components comprises polyester, and wherein the polyester comprises polyethylene terephthalate (PET), polybutylene terephthalate (PBT), or polytrimethylene terephthalate (PTT). 
     
     
       12. The bi-component continuous filament of  claim 1 , wherein the polymer of the first polymer component is different than the polymer of the second polymer component. 
     
     
       13. The bi-component continuous filament of  claim 1 , wherein the bi-component continuous filament exhibits a denier per filament (DPF) ratio measuring from approximately 2 DPF to approximately 30 DPF. 
     
     
       14. The bi-component continuous filament of  claim 1 , wherein the bi-component continuous filament exhibits a weight measuring between approximately 500 denier to approximately 3500 denier. 
     
     
       15. The bi-component continuous filament of  claim 1 , wherein the polymer of the first polymer component is different than the polymer of the second polymer component. 
     
     
       16. The bi-component continuous filament of  claim 1 , wherein:
 (a) the acid anhydride comprises maleic anhydride; and 
 (b) the polymer of the first polymer component is different than the polymer of the second polymer component. 
 
     
     
       17. The bi-component continuous filament of  claim 1 , wherein the tenacity of the bi-component continuous filament is between 3.39 and 3.85 grams/denier. 
     
     
       18. The bi-component continuous filament of  claim 1 , wherein the tenacity of the bi-component continuous filament is between 3.55 and 3.85 grams/denier. 
     
     
       19. The bi-component continuous filament of  claim 1 , wherein the elongation of the bi-component continuous filament is between 35.39%-37.64%.